Investigating the Effective Factors for Enhancing the Optimization of Al6061/8Al2O3-3WC-8SiC Composite Using the Friction Stir Process

Document Type : Research Article

Authors

1 Department of Materials Engineering & Interdisciplinary Sciences, Shahid Rajaee Teacher Training University, Tehran, 1678815811, Iran

2 Department of Mechanical Engineering, Shahid Rajaee Teacher Training University, Tehran, 1678815811, Iran

3 Department of Materials Engineering, Hamedan University of Technology, Hamedan, 65155579, Iran

Abstract

Friction Stir Processing (FSP) is an advanced solid-state technique widely recognized for its ability to enhance the microstructural and mechanical properties of materials, particularly in the fabrication of surface composites. This study investigates the application of FSP to fabricate a surface composite based on Al6061 alloy, reinforced with 8% Al₂O₃, 3% WC, and 8% SiC particles, aiming to improve its mechanical performance. A series of experiments was conducted to evaluate the effects of varying rotational and linear speeds on the processed samples. The results revealed an 89% reduction in grain size within the stir zone, decreasing from 92 ± 8 µm to 10 ± 1 µm, accompanied by a significant increase in hardness from 44 HV₅₀ to 61 HV₅₀, representing a 38.6% improvement. Increasing the number of FSP passes further enhanced hardness, with values of 53 HV₅₀, 60 HV₅₀, and 61 HV₅₀ for one, two, and four passes, respectively, indicating a 15.1% increase. A consistent ratio of 25 between rotational and traverse speeds was identified for aluminum alloy 6061, emphasizing the importance of precise parameter control. The optimum processing parameters were determined to be a rotational speed of 1000 rpm, a traverse speed of 40 mm/min, and four passes. Moreover, the incorporation of reinforcing particles significantly improved hardness, increasing from 50 HV₅₀ to 61 HV₅₀, a 22% enhancement, highlighting their critical role in strengthening the material. These findings demonstrate the potential of FSP as a highly effective method for optimizing material performance, offering valuable insights for applications in industries such as automotive, medical, and railway transportation.

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Main Subjects

References

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Mechanics of Advanced Composite Structures
Volume 13, Issue 2 - Serial Number 28
In Progress
November 2026
Pages 371-379

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